Method of manufacturing a magnetic read/write head and slider assembly

ABSTRACT

A method of fabricating a magnetic read/write head and slider assembly, wherein the assembly has improved heat spreading and dissipation properties and the read/write head exhibits significantly reduced thermal protrusion during operation. The method of fabrication is simple and efficient, involving only the extension of at least one of the conductive mounting pads so that it is in thermal contact with a portion of the slider surface that is directly above the read/write element.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to the fabrication of merged magneticread/write heads and slider assemblies and, more particularly, to thefabrication of such a head and slider assembly with improved heatspreading and dissipation characteristics to eliminate problemsassociated with thermal expansion and protrusion of head elements duringoperation.

2. Description of the Related Art

A merged magnetic read/write head and slider assembly consistsessentially of a magnetoresistive read sensor element formed on the polepieces of an inductively magnetized write element and mounted within, orfabricated as an integral part of a slider assembly that physically andelectrically connects the head to an actuator arm. The read/write headis subjected to complex thermal stresses during its normal operation dueto the buildup of thermal energy from Joule heating in its read andwrite stages (sensing current in the read element and write current inthe write coil). The heat dissipation properties of the read/write headare limited by the thermal conductivity of the protective overcoatmaterial (typically sputtered alumina) that covers the head. Sincealumina is a relatively poor conductor of heat, a temperature buildupoccurs in both the head and the overcoat as the overcoat is unable toeliminate the heat produced in the head with sufficient rapidity.

FIGS. 1 and 2 show two schematic views of a read/write head and sliderassembly. FIG. 1 shows a cross-section of the head attached at (15) tothe actuator arm (30). Details include the overcoat (2), the upper (6)and lower (4) pole-pieces and the insulation imbedded coil structure (5)that inductively activates them. The read element (8) is generallyformed beneath the lower pole piece (4) which then also serves as anupper shield for the read head. The air-bearing surface of the head, atwhich the read element is positioned, is indicated as (1) and thedimensional direction “x” is also shown. The trailing end, containingthe connecting pads (only (10) is shown), is indicated as (14). FIG. 2is a schematic drawing showing the trailing end surface (14) of theread/write head assembly where it attaches to external wiring (shown as(13) in FIG. 1) along the actuator arm. The dimension “z” on the drawingwould be coming out of the plane of the drawing in FIG. 1. FIG. 2 alsoshows four gold pads (16, 18, 20, 10) which make the electricalconnections to the head assembly. Two of the pads (10 & 20) provide thesense current for the read sensor through internal wiring (9), while theremaining pads (18, 16) provide the coil current for the write headthrough wires (19). These figures will also be discussed below in thecontext of the description of the preferred embodiment.

Seagle (U.S. Pat. No. 5,936,811) provides a slider assembly similar tothat in FIGS. 1 & 2 in which the current carrying leads are disposed ina manner that eliminates the need for vias passing through theinsulating layers and shield layers to allow the electrical activationof the read and write sensors.

Chang et al. (U.S. Pat. No. 6,158,107) provide a merged read/write headin which the pole tips of the write head are more advantageously definedby use of a self-alignment formation process and show the use of asubstantial overcoat in the head formation.

Maries et al. (U.S. Pat. No. 3,770,403) discloses a magnetic headassembly in which the read/write circuit portions of the assembly areformed on a chip and bonded to head assembly by a glass-ceramic materialwhose coefficient of expansion matches the coefficient of expansion ofthe parts to be joined. Another feature of this structure is that themethod of mounting the head assembly on the support arm allows the airflow past the assembly to act as a coolant for the circuit chip and alsoallows the thermal conductivity of the metal structure of the arm to actas a heat sink for the circuit chip.

Phipps et al. (U.S. Pat. No. 5,757,590) deals with the problem ofelectrostatic charge buildup on read/write heads, which is anotherproblem associated with rapid relative movement between the head and therecording medium. Phipps provides a fusible link element connectedacross the existing terminal pads of the head to discharge the unwantedbuildup.

Wang et al. (U.S. Pat. No. 6,130,863) show the use of a magnetic coiland slider assembly even in the field of magneto-optical storagesystems.

Han et al. (U.S. Pat. No. 6,103,136) shows a magnetoresistive read headthat typifies those found in the merged read/write heads referred to inthe present invention.

None of the prior art cited deals with the significant problem of heatbuildup in head elements such as write coils, magnetic pole pieces,overcoat regions and magnetoresistive sensing formations. This heatbuildup is not only damaging to the performance of the elements, butdifferential thermal expansion causes protrusion of elements relative toeach other and relative to the air bearing surface, which protrusion cancause damage to the rapidly moving storage medium. It is, therefore, thepurpose of the present invention to provide a simple and efficientmethod whereby the heat dissipation properties of a read/write elementcan be significantly improved.

SUMMARY OF THE INVENTION

A first object of this invention is to provide a method for forming amagnetic read/write head and slider assembly having improved heatspreading and dissipation characteristics when compared to magneticread/write heads and slider assemblies of the prior art.

A second object of the present invention is to provide a method forforming such a magnetic read/write head and slider assembly havingimproved heat spreading and dissipation characteristics, wherein saidmethod of formation is simple and efficient and requires only a slightvariation in the present method of forming such a head and slider.

A third object of this invention is to provide a magnetic read/writehead and slider assembly having significantly improved heat spreadingand dissipation characteristics.

A fourth object of this invention is to provide a read/write head andslider assembly wherein there will be no protrusion of head elements andovercoat relative to the air bearing surface of the head during normaloperating conditions.

In accord with the objects of this invention there is provided amagnetic read/write head and slider assembly and a method for formingsuch a magnetic read/write head and slider assembly, wherein one of theelectrically conductive pads that connects the internal current carryingleads of the head to the external circuitry is enlarged and extendedover a substantial portion of the bottom of the slider (the trailing endsurface) so that it covers and thermally contacts the portion of theovercoat that is above the head structure. Since said pad is typicallyfabricated of gold or other material that is both electrically andthermally highly conductive, much more thermally conductive than theovercoat material, the enlargement and extension of the pad providessignificant additional heat spreading (reduction of sharp temperaturegradients) and heat dissipation for the head and slider assembly. Sincethe external electrical leads connected to the pads offer additionalheat dissipation, the effect is magnified and rendered even moreadvantageous.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects, features and advantages of the present invention areunderstood within the context of the Description of the PreferredEmbodiment, as set forth below. The Description of the PreferredEmbodiments is understood within the context of the accompanyingfigures, wherein:

FIG. 1 is a schematic drawing of a cross-section of a magneticread/write slider/head assembly that is representative of both the priorart and the present invention. For purposes of discussion, the plane ofthe cross-section is the x-y plane and x denotes the slider lengthdirection.

FIG. 2 is a schematic drawing of the top surface configuration (trailingend of the slider) of a read write head fabricated in accord with theprior art. The plane of this drawing is the y-z plane relative to thedrawing of FIG. 1. The trailing end surface displayed represents thesurface of attachment of the slider/head assembly to the external wiresalong the actuator arm assembly.

FIGS. 3 and 4 are the graphed results of simulations carried out to showthe temperature profile in the x-direction (FIG. 3) and the z-direction(FIG. 4) across a head of the prior art during normal operatingconditions.

FIGS. 5 and 6 show graphed simulation results of the protrusion profilesof the head and overcoat regions corresponding to the temperatureprofiles of FIGS. 3 and 4 respectively.

FIG. 7 is analogous to FIG. 2, being a schematic view of the rearsurface of a slider/head assembly whose connective pads are formed inaccord with the methods of the present invention.

FIGS. 8 and 9 are, respectively, graphical representations of simulatedtemperature profiles in the slider length direction (x) and the sliderwidth direction (z) for a slider fabricated in accord with the method ofthe present invention. Each graph also shows the corresponding graphsfor a reference slider fabricated in accord with the prior art.

FIGS. 10 and 11 are graphical representations of simulations of thethermal protrusion profiles corresponding, respectively, to thetemperature profiles of FIGS. 8 and 9.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of the present invention provides an efficientand effective method for materially improving the heat dissipation andheat spreading characteristics and eliminating associated thermalprotrusion problems of a merged magnetic read/write head and sliderassembly by the enlargement of at least one of its current leadconnecting pads. The efficacy of this method has been substantiated bysimulations that compare heads fabricated according to the method of theinvention with heads fabricated according to methods of the prior art.

Referring first to FIG. 1, there is shown a schematic, not-to-scale,cross-sectional diagram of a read/write head and slider assembly typicalof the prior art, mounted on an actuator arm assembly at its trailingend surface. For the purposes of description, the cross-sectional planeis the x-y plane as shown in the diagram and the z-axis can be taken ascoming out of the plane. The air bearing surface (ABS) of the head isdenoted as (1). The head comprises a magnetoresistive read sensorelement (8) formed contiguously with the lower magnetic pole piece (4)of an inductive magnetic write element which also serves as an uppershield for the read element. The upper pole piece is of the writeelement is (6). Between the upper and lower pole pieces can be seen thecross-sections of the energizing coil turns (5) which are encased in aprotective medium (12). The read element is shielded below by (3). Thepole pieces come together to form a write gap (7). A protective overcoatsurrounds the entire formation (2). Typically four internal conductiveleads (three not shown) would emerge from the head and terminate atconnecting pads (only (10) is shown) on the trailing end surface of theslider assembly, two leads to provide energizing current to the coil andtwo leads to provide sensing current to the read head. Only one suchinternal conducting lead is indicated (9) and that lead is shownterminating in a conductive pad (10) that emerges at the trailing end ofthe head (14). In actuality, there would be four such pads, one attachedto each of the internal leads, said pads providing the electricallyconducting contact to the external circuitry. The slider assemblyconnects to the actuating arm (30) along surface (15) to complete thefabrication, with the pads (10) providing the means for connecting the(partially drawn) internal conducting leads (9) to external leads (13).

Referring next to FIG. 2, there is shown a schematic drawing of thesurface of the trailing end of the read head, which is shown only as(14) in FIG. 1. The plane of the surface is the z-y plane. The drawingshows the trailing end surface (14) and all four of the conductive pads(10), (18), (16), (20). The pads connect by conducting lines (19), (9)beneath the surface (drawn as dashed lines) to the write coil leads andread element (neither shown) within the head (12), which is also beneaththe surface and drawn as dashed. Referring next to FIG. 3, there isshown a graph of temperature (° C.) vs. distance (in microns) in thex-direction or slider length direction (see FIG. 1) resulting from asimulation of a read/write head of the prior art under operatingconditions. The x=0 position corresponds to the bottom of the head, x=20microns locates the top of the head and the region from x=20 microns tox=35 microns encompasses the overcoat. As can be seen from the graph,there is a sharp temperature peak near the overcoat boundary which is aresult of the poor heat conduction through the overcoat material.

Referring next to FIG. 4, there is shown the temperature distribution ofFIG. 3 as measured (by the simulation) in the z-direction (sliderwidth). Once again, the temperature is peaked in the read head region.

Referring next to FIGS. 5 and 6, there is shown graphical evidence ofhead and overcoat protrusion (in nanometers) produced by the temperaturedistributions in FIGS. 3 and 4. In this particular case, the maximumprotrusion occurs in the overcoat region.

Referring next to FIG. 7, there is shown a schematic drawing of thetrailing surface of a slider fabricated according to the method of thepresent invention. This figure is to be compared to the illustration inFIG. 2, which shows the corresponding surface of a prior art slider. Ascan be seen in FIG. 7, pad (16′), which corresponds to pad (16) of FIG.2, has been substantially extended (17) to cover the head region (12)(beneath (17)). Said pad is formed of a metal, such as Au, Ag, Al or Cu,which is both electrically and thermally conductive. In practice, anygood heat and electrical conductor that can be efficiently and easilyplated on the overcoat material can be used. In the present embodiment,Au is used because it is easily plated on the alumina overcoat andbecause the remaining conductive pads are also Au. Heat generated withinthe head region beneath (17) is, therefore, efficiently transferred tothe pad extension by conduction, is spread through both the pad andassociated external wiring that it is attached to and is dissipatedthereby. Given the purpose served by the pad extension, it should beseen that the shape of the extension is not critical, but it should beof sufficient area to completely cover that region of the trailing endsurface that is directly over the read head, while not being of so largean area as to interfere with the other connecting pads. In the presentembodiment, the Au pad extension, which is plated through a mask, isapproximately square in shape and approximately 200 microns by 200microns in size (area) and approximately between 4 and 5 microns inthickness.

Referring next to FIGS. 8 and 9, there are shown simulated temperatureprofiles along the x (FIG. 8) and z (FIG. 9) directions for a sliderfabricated according to the method of the present invention (10) and fora slider fabricated according to the prior art (20). The prior artslider profiles are the same as those in FIGS. 3 and 4.

Referring finally to FIGS. 10 and 11, there are shown the protrusionprofiles corresponding to the temperature profiles in FIGS. 8 and 9.Once again, (10) indicates the invention and (20) indicates the priorart. The significant reduction in protrusion is readily apparent.

As is understood by a person skilled in the art, the preferredembodiment of the present invention is illustrative of the presentinvention rather than limiting of the present invention. Revisions andmodifications may be made to methods, materials, structures anddimensions employed in the present method of fabricating a magneticread/write head and slider assembly with improved heat dissipation andthermal protrusion properties, while still providing a read/write headand slider assembly with improved heat dissipation and thermalprotrusion properties, in accord with the spirit and scope of thepresent invention as defined by the appended claims.

1. A method for fabricating a magnetic read/write head and sliderassembly having improved heat spreading and heat dissipationcharacteristics and reduced thermal protrusion comprising: providing amagnetic read/write head and slider assembly on whose trailing endsurface are formed a plurality of electrically isolated pads which areboth electrically and thermally conducting, said pads providingelectrical connections between said read/write head and externalcircuitry by means of internal current leads connected between said padsand said read/write head; forming at least one of said pads with alarger surface area than other said pads by the addition of an extensionthereto, said extension having an area that is at least the area of thepad to which said extension is added and said pad with said extensionhaving, thereby, a surface area covering at least that portion of thetrailing end surface that is directly above said read/write head andsaid pad with said extension being in thermal contact with said trailingend surface.
 2. The method of claim 1 wherein the pads are formed ofgold and said pad with the larger surface area is between approximately4 microns and 5 microns in thickness and comprises a square of sidebetween approximately 50 microns and 250 microns and an extension ofside between approximately 150 microns and 250 microns and wherein theshape and dimensions of said extension is sufficient to cover an area ofthe trailing surface that is directly vertically above the read/writeelement.